International Journal of Physical and Social Science

Vol. 8 Issue 11, November 2018

ISSN: 2249-5894 Impact Factor: 6.644
Journal Homepage: http://www.ijmra.us, Email: editorijmie@gmail.com
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Industrial Safety : Precaution for Thermic Fluid Heaters

SAFETY AUDIT OF THERMIC FLUID HEATERS

vasudev Kulkarni

( UNDER RULE 73-ZA OF THE MAHARASHTRA FACTORIES RULES -1963 ) ( RULES

PRESCRIBED UNDER, READ WITH SECTION 112 OF THE FACTORIES ACT, 1948 )

Introduction :

Due to various technical reasons and advantages, a trend of uses of Thermic Fluid Heaters in the

factories, in various manufacturing processes are on increase. However, the Thermic Fluid Heaters are prone to

certain dangers and therefore rules are prescribed, to ensure safety under rules 73-za Maharashtra Factories Rules

-
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1963; read with section 112 of The Factories Act, 1948.

Taking into account various provisions, a ready reckoner - check list, is prepared for the guidance, simplifying the

complexity of provisions. This is tabulated and can be used for safety audit of Thermic Fluid Heaters, as under:

Check list and synopsis of provisions under Rule 73-Za of The Maharashtra Factories Rules -1963; for Thermic

Fluid Heaters, as tabulated under.

(1)
A Research Paper / Article on, Industrial Safety : Precaution for Thermic Fluid Heaters

SAFETY AUDIT OF THERMIC FLUID HEATERS

(RULE73-ZA OF MAHARASHTRA FACTORIES RULES -1963)

CHECK LIST AND SYNOPSIS OF PROVISIONS UNDER RULE 73-ZA OF THE MAHARASHTRA
FACTORIES RULES 1963
OF THERMIC FLUID HEATERS
SR.
NO. SYNOPSIS PROVISION AS PER RULE (1) AUDIT / PRESENT STATUS REMARKS

1) Construction of (i)all heater shall be of

Coil (Type of Coil such construction that, Removable
the coils shall be
: removable for periodic Coil
Removable) cleaning, visual
inspection & hydraulic Not Removable
test

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2) (ii) suitable arrangements shall Provided

Cooling System of be made for cooling the furnace Effective
effectively in case of power cooling
Furnace
failure to the heater
(When power failure) system
Not Provided

3) Purging
System iii) before restarting the Done
(Before restarting) furnace of heater it shall Purging
be effectively purged. Not Done

4) Expansion Cum Done

Deaerator Tank Expansion
and its Location tank
(outside the (iv)the Thermic fluid used Not
shed) for heater shall be Done
circulated in a dosed
circuit formation with an
expansion cum decrator
tank. This tank shall be Outside Shed
located outside the shed Location of Tank
where the heater is Other
installed. (In side shed)
(2)
5) Flame Failure (v) every oil or gas fired Photo Resister Provided

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indication & heater shall be provided Actuated Audio Not

Automatic Bumer with a photo-resistor visual alarm Provided
cut off system (For actuated audio visual (For Flame Failure)
Oil & Gas fired alarm to indicate flame
heaters) failure and automatic Automatic
Automatic
burner cut off.
Burner cut off
System
Manually
(After Flame failure)

6) Stack temperature (vi) the stack temperature Provided

Monitor cum monitor cum controller
with audio visual alarm Stack Temp.
Controller (Audio / shall be provided to the Monitor Not
Visual) heater so as to warn the
operator in case the Provided
outlet temperature Provided
(Where outlet exceeds the specified Controller
temperature minimum.
exceeds) Not
Provided
Audio Visual
Alarm Provided

Not
Provided

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7) Indicating (vii) all heater shall be

Devices and their provided with following
efficient devices and the same
maintence shall be maintained in
Provided
efficient working order.
Level Indicator in
expansion tank
Not Provided
(3)
Conted. Page 3
(a) level indicator in the
expansion tank
(b) temperature indicator of
thermic fluid. Provided
Temp. Indicator of
(c) different pressure switch Thermic Fluid
across the inlet and the Not Provided
outlet line of the hearter
tubes, and
Separate pressure Provided
(d) temperature control Switches
devices for the fuel acros inlet &
supply to the burner. outlet of tubes
Not Provided

Provided

Temp.
Controller of fuel

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supply of the burner

Not Provided

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8) Inter locking of (viii)all devices mentioned in

Indicating devices clause above for oil or
gas fired heater shall
have inter locking
arrangement with burner
so that in case of any
predetermined limits
being crossed the supply
of fuel and air to burner
shall automatically be
cut-off.

Provided
Inter locking with
Burner level
Indicator
Not Provided
Provided
Temp. indicator of
Thermic fluid

Not Provided

Provided
To pressure
switches
Not Provided
(4)
Conted. Page 4

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9) Audio Visual Alarm (ix) all safety inter-locks when Yes

(of all safety inter operated shall be All Inter locks,
locks) indicated or on the indicators By
control panel of the Audio
heater by a suitable audio
visual alarm. visual alarm No
10) Electrical Panel (x) electrical Panel for the Near heater
(Location) heater shall be located Location of
near the heater but not Panel
so close as to be
exposed to spilling or
leaking oil. Close to heater
(Spilling / Leaking oil)
11) Segregation of (xi) te heater shall be Yes
located in a place Segregate from
Heater (From other
segregated from other other
Mfg. manufacturing activities. Maufacturing
Acivities) Activities.No
12) Explosion Vent (xii) explosion vent for Location ofYes
(Safe location) heater shall be Release of
installed that the Explosion Vent
release takes place No
at safe location. is at safe place

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13) Pressure Testing Yes

(viii) the heater coil including Heater Coil
(Period) the coil connected to it in Testing by
(once/12 Months) the user's equipment Competent every
(Max. test subjected to pressure 12 months.
Pressure >= 2 O. shall be tested by (Carried out)No
P. competent person once
at least in every 12 Yes
months. The test Coil connected to
pressure shall not be less user's equipment
than twice the operating No
pressure.
(Test by competent every 12 months)
(5)
Conted. Page 5

14) Repairs (xiv)if repairs are carried out to Examination of Yes

the heater, coil including Heater Coil & users Coil by
coil connected it in users competent before taking
equipment shall be got
examined from competent
into use
person before taking it into
use. No
15) Temperature of (xv) maximum temperature of Max. Temp. of T. F. -
Thermic Fluid thermic fluid in the a)Recommended by mfgrs :-
(Max. temp. as per heating of heater coil b)Actual Working Temp :-
Mfg's shall not exceed the
Specifications) figure specified by the
T. F. Specification Prescribed
manufacturer. The
Other test : thermic fluid used in Mfgs Present Remark
Acditiy heater, shall conform to
the specifications
Suspended
prescribed by the a) Acidity

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Matter manufacturer & shall be b) Suspended

Ash Contents tested by competent
Mater
Viscosity person for suitability at
least once in every three c) Ash Contents
Flast Point
months period. Such d) Viscosity
(once in 3
test shall include test for
months) e) Fast Point
acidity, suspended
matter, ash contents, Frequency of test- (Once in 3 months)
viscosity and flash Point
16) Cleaning of Heater (xvi)cleaning of the internal Cleaning - Done
Internal surface surface of the heater of Internal
Removing soot for removing soot & surface of
Check up check up the refactory
refactory / surface on the inside
/ month Heater
shall be carried out
Cleaning of every month, or as (Frequency) :
surface of often as required Every Month)Not Done
Coil / 6 months depending upon
Cleaning of working conditions. Check up of
Burner The coils of heater RefactoryDone
Nozzels shall be removed & Surface
surface of the coil (Per Month)
cleaned Not Done
(6)
Conted. Page 6

Oil filters / Pump throughly once atleast in

a period of six months. Done
Cleaning of
The burner, nozzles, oil Surface Coil
filters (Frequency :
& pumps shall be cleaned
once a week during the Every 6 Months) Not Done
period of
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use. Cleaning of
Burners - Once a week
Nozzels - Once a week
oil filter - Once a week
pumps - Once a week

17) Maintence of (xvii)a separate register Maintained

Register/ Records of containing the following Registers
information information for the Not
for heater shall be Maintained
maintained
* Weekly Check
(a) weekly check carried
(effectiveness of Weekly Checu up :
out confirming the
inter locks)
* Weekly Check effectiveness of the
(All accessories are inter-lock;
in good state of (b) weekly checks Maintained
repairs) confirming in good of (A) Effectiveness of
repairs; and (c) inter locks Not Maintained
information regarding fuel (B) All accessories (In
* Records of
oil temperature, Pressure, good state of repaires)
informationregarding
thermic fluid inlet/outlet Records
/ every 4 Hrs. pressure & temperature,
- Fuel oil Temp. fuel gas temperature,
- Pressure recorded at four hourly
- Thermic Fluid interval.
inlet / out let - Maintained
Pressure Gauge
Pressure & Temp.
Not Maintained
_ Fuel gas temp.
(7)
Conted. Page 7

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Maintained
Temp. Gauge
Not Maintained

Maintained
Pressure
Switches
Not
Maintained

Maintained Explosion Vent.

Not
Maintained

(C) Records of
following at four hourly
intervals.
Maintained 1) Fuel
oil temp.
Not
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Maintained
Maintained
2) Fuel oil
pressure Not Maintained
Maintained
3) T. F. inlet
pressure Not Maintained
Maintained
4) T. F. outlet
pressure Not Maintained

(8)
Conted. Page 8

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Maintained
5) T. F. intlet
tempreture Not Maintained

Maintained
6) T. F. outtlet
tempreture Not Maintained

Maintained
7) Fuel gas
tempreture Not Maintained

18 Heater under (xviii.) the heater when in

trained operation shall always Maintained
Operator be kept in charge of a Incharge
trained operator. (Operator)
Not Trained

(# Note : Any errors here, in provisions, to be ignored and to be

referred to the original text of the rule.)

Researcher :
(Author)
V. G. Kulkarni
[ A Research student (Law), SPPU, Pune ]

vgkulkarni108@gmail.com
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